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The principle of gear skiving was invented back over a century ago. Yet in practice the highly dynamic kinematics involved in this method frequently caused major problems: to date this method offered more disadvantages than benefits, as tool wear and tear had a negative impact on machining quality. Liebherr-Verzahntechnik GmbH has now mastered both the mechanics and the technology involved, meaning it is now in a position to create the ideal process for conical and cylindrical tools.

It is easier said than done – if it takes too much time for two processes to run consecutively on a single machine or single clamping operation, then the design must simply allow both processes to take place simultaneously. As easy as the principle sounds, technical implementation is very complex. We have integrated an entire second processing unit for ChamferCut tools – two machines in one, so to speak. This newly developed solution has eliminated the main disadvantage of previous ChamferCut applications, namely that they prolong machining time.

Industry 4.0 is a trend that has been prevalent for some time. This transformation via the “smart product” to the “smart factory” is a continuous process. Our customers have very different priorities and requirements, which we need to meet to their complete satisfaction. This is a challenge that we are keen to take on.

Nowadays operators should be able to perform highly complex procedures as simply as possible. To make this happen, they need the appropriate technical support. This support is to be found in modern user interfaces, which also reduce the incidence of problems due to input errors. Thus, for example, our new HMI, LHGe@rtec, enables hob data to be loaded directly from the manufacturer into the machine. The tools and tool data are then displayed and can immediately be visually checked for completeness and accuracy. The new HMI’s multi-touch function caters for modern forms of machine operation. This graphic input support is also available for operator-created part programs.

Distortion-free topological grinding for twist-corrections

We have not re-invented generating grinding, but we have reached a higher level of understanding about it. With the new procedure, Liebherr makes absolutely deviation-free generating grinding with topological modifications possible. The procedure has been registered with the patent office and is of great interest in relation to gearboxes for reasons of load rating and noise minimisation. Until now, there has not been a cost effective grinding method to do this.

The advantages of microgeometry corrections for gears:

Unique opportunities through microgeometry

Same load carting-capacity with smaller face widths

Noise minimisation

Most cost effective solutions for generating grinding of topological modifications

LCD 300 chamfering and deburring machine: Chamfering to measure

The trend is moving towards more efficient and quieter gearboxes, particularly in the automotive industry. This means that the demands on individual components are higher: Special gears need to be machined with clean edges. Chamfering helps to avoid damage during workpiece transportation, hardness cracks and gearbox wear from sharp edges. Moreover, chamfering simplifies the assembly process and improves the service life of the tool during finishing and honing, in particular.

Effective automation for small batch sizes – even in heavy duty applications with the PHS 10,000 pallet handling system from Liebherr

Manufacturers of small batch sizes are familiar with the dilemma: If there is no harmony in tooling and operating times, the downtimes of the machines rise. In addition, trips need to be made for retooling that take up a lot of time and are quite complex in terms of logistics. But this problem can be resolved by separating the tooling area and the machine. This tooling area is embedded in the trusted PHS pallet handling system from Liebherr where the workpieces and equipment are located. Stefan Jehle, Head of Automation System Sales, describes the principle as follows: “Man has to be taken away from the machine. At the moment, the machine is often the conductor that determines the rhythm. With clever automation, the process can set the degree to which the machine's capacity is utilised. The conductor stand is in the tooling area that a person co-ordinates.”

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